Dave's la(te)st buggy build...

I did intend to Kirkynut, I’d ordered new bolts in my order from the BigJimny store, and I was going to chop the backing plates into little squares around the join, BUT... when I stripped everything they weren’t rusty at all, so I left them intact...

No work on Wednesday as my member of staff for the day texted in sick

Out there tomorrow spannering though... dropping the transfer box out for some fettling - breather and new mounting brackets and bush stacks...

Dave

Bit more today...

Having finished the front axle's rebuild / steering / suspension I thought I'd carry on 'underneath' and get the rest of the transmission sorted, that then leaves me to shape the body, etc over the winter...



Fought to get the transfer box off... the rear prop's bolt refused to move so it came out still attached...!



A piece of angle iron across two flange bolts stopped the box turning while I fought to get the rear prop off on 'the bench'



I eventually won!



Front prop marked and then split to replace the torn boot and regrease...



Both props cleaned a little and set to one side...



And I then stripped the brackets off the transfer box, and then...



Gave it a damn good clean with degreaser... so it's all ready for the breather to be fitted and some new mounts to be fitted...

Just checking out Martin's instructions for the breather kit , on which my installation is based.

On Wednesday hopefully?

Box looking nice and clean
Just a little tip for tapping if you have a strong magnet sit it on top of the tap wrench
with a small amount of grease on the tap
will reduce swarf getting into the box

Thanks jackonlyjack

I'll do that and also swill and empty the box with a bit of oil a couple of times too, being as it's out and 'on the bench'

I've even cut a hole in the bench to allow the box to sit upside down -



to work out the mounts...

No, no 'lobster in this one, trying to do it "on the cheap" !

In this one the diffs have been changed from the early 3.9's to later VVT 4.3's - that should compensate for the 29" tyres...

Yes, it came up looking good, I know it's a bit of a waste of time, but it does make it a lot easier to handle as I fabricate the new tougher mounting for it...

Gus/Chris was selling some steel HD mounts ask him for a price
easier to weld a cradle to ready made mounts

Nice work Dave,

I wish the axle on my Surf was that clean.

Paul.

jackonlyjack wrote: Gus/Chris was selling some steel HD mounts ask him for a price
easier to weld a cradle to ready made mounts

Thanks jackonlyjack... I did have a look through Gus's list and thought about them... BUT I still have the jig I made to manufacture a small initial batch of transfer box mounts as ZookBOB so I'll be using that to make somr mountings (yes, a cradle as it happens )

I'm trying to make / do as much as I can myself to keep the costs down, although saying that a box arrived from JimnyBits this morning, as when I was lying under the Jimny buggy wrestling the transfer box out I couldn't help but notice how vunerable the fuel tank is?! So there's a guard for it in the box
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Paul_sterling wrote: Nice work Dave,

I wish the axle on my Surf was that clean.

Paul.

Thanks Paul, ironically I can't wait to get it dirty again

Dave

This is the jig I mentioned above -



You can justa bout see the dowels pointing through the 4 mounting holes, nd the box section mount has two holes corresponding with two holes in the steel plate base, a couple of bolts through them and line the pegs up and we're good to weld... usually... but I want these to be a bit longer...



So mockup the mounts and then...



Turn the box over with the lever through the peep hole in the 'bench; and start looking at the angles...



And then the other side...



Experiment with some cardboard!



We shopkeepers have plenty of cardboard boxes lying around



Happy with the design so transfer it to 5mm steel plate!



Voila!



And then cut it out with a bigger pair of scissors, or even an angle grinder



Cut two thirds through the plate to make the bends...



And the beaver away forgetting to take more photos! F'Oh!



Almost done but run out of time....





Will finish it off on Sunday

Nice one Dave! that looks a sturdy bit of kit